Unattended spot cleaning apparatus

ABSTRACT

A spot cleaning apparatus comprises a housing, a fluid distribution system, a fluid recovery system, an agitation system, and a controller system to automatically monitor and control inputs and outputs to said systems for removal of spots and stains from a surface without attendance by a user. A suction nozzle and agitation device are mounted to the housing for movement over the surface to be cleaned relative to a stationary housing. Optionally, the spot cleaning apparatus can be operated in a manual mode.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional application Ser.No. 60/320,071, filed Mar. 31, 2003, which is incorporated herein byreference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to extraction cleaning devices. In one of itsaspects, the invention relates to an extraction-cleaning machine that isadapted to clean spots in carpet and other fabric surfaces. In yetanother aspect, the invention relates to an extraction cleaning machinewith an improved scrubbing or agitation implement. In yet anotheraspect, the invention relates to an extraction cleaning machine with anair purifier. In yet another aspect, the invention relates to a spotcleaner for carpet and bare floors that can function unattended by auser. In yet another of its aspects, the invention relates to a floorcleaning apparatus that has a cord wrap that can be retracted into theapparatus housing when not in use.

2. Description of the Related Art

Japanese Patent Application Publication No. 04-042099, published Feb.12, 1992, discloses a stationary floor cleaning device for removal ofradioactive material. To operate the device, the user manuallyselectively actuates three electrical switches to activate a vacuummotor, a fluid delivery pump or a rotating brush.

U.S. patent application Ser. No. 09/755,724, published on Dec. 6, 2001,discloses an upright deep cleaning extraction machine comprising a basemovable across the surface to be cleaned, an upright handle pivotallyattached to the base, a fluid distribution system, a recovery system andan agitation system. The fluid distribution system comprises a cleanfluid tank, a delivery valve and a spray nozzle, each of which are influid communication via a conduit. Upon activation of the deliveryvalve, fluid is delivered under force of gravity through the spraynozzle and onto the surface being cleaned. A suction nozzle is locatedat a forward end of the base and provides an entry point for liquidextraction through a working air conduit that is in fluid communicationwith a dirty water recovery tank. A vacuum motor driving a fan ispositioned downstream of the recovery tank to create a working airflow.A rotating scrubbing implement is mounted horizontally in spacedrelation behind the suction nozzle. The brush can be rotated via a beltdriven by the vacuum motor or alternatively via an air driven turbine.

U.S. Pat. No. 6,446,302 to Kasper et al. discloses an extractioncleaning machine with floor condition sensing devices and controllersfor the cleaning operation. A controller sends signals to a variablecontrol cleaning system in response to signals received from thecondition sensors. The condition sensors and controllers are mounted toan upright deep cleaner wherein movement of the cleaner can beaccomplished by motive force generated by the user.

U.S. patent application Ser. No. 10/065,891 to Lenkiewicz discloses acommercially available portable extraction cleaning device known as theBISSELL Little Green Clean Machine Model 1400, 1425, or 1425-1 thatincorporates a fluid distribution and recovery system similar to that ofa larger extraction device in a smaller configuration.

SUMMARY OF THE INVENTION

According to the invention, a floor cleaning apparatus comprises ahousing that mounts a fluid delivery system including a fluiddistributor for delivering a cleaning fluid to a surface to be cleaned,a fluid extraction system including a suction nozzle for recoveringsoiled cleaning fluid from the surface to be cleaned and, optionally, ascrubbing implement for scrubbing contact with the surface to becleaned.

In one embodiment, the housing has a bottom portion that is adapted torest on a surface being cleaned and a carriage assembly support above anopening in an underside of the housing. A carriage mounts the fluiddistributor and the suction nozzle to the carriage assembly support fortranslational movement with respect to the housing so that the suctionnozzle and the fluid distributor move laterally with respect to thesurface to be cleaned in the opening in the housing.

Preferably, the scrubbing implement is mounted to the carriage formovement with the fluid distributor and the suction nozzle. Preferably,the scrubbing implement is a brush but it can also be a cloth or a foampad. Further, the scrubbing implement, the fluid distributor and thesuction nozzle move as a unit with respect to the housing.

In a preferred embodiment of the invention, a resilient biasing elementis mounted between the carriage and the carriage assembly support forresiliently biasing the suction nozzle and the scrubbing implement, ifany, onto the surface to be cleaned. The biasing force of the biasingelement is less than the weight of the housing.

In one embodiment of the invention, the translational movement isorbital. In this embodiment, the carriage includes a gear system formotion of the fluid distributor and the suction nozzle with respect tothe housing.

In another embodiment, the translational movement is linear. In stillanother embodiment, the translational movement is circular.

The fluid distributor can take a variety of forms. In a preferredembodiment, the distributor comprises one or more spray nozzles.Alternatively, the distributor can be a manifold with spaced openings.

The suction nozzle is typically an elongated slot but can take a varietyof shapes. In one embodiment, the suction nozzle is L-shaped. In anotherembodiment, the suction nozzle is T shaped.

Typically, the carriage will be driven by an electrical motor although amanual crank can also be used to drive the carriage. Preferably, a motormounted to the housing and connected to the carriage for driving thetranslational movement of the carriage with respect to the housing. Apower supply for the motor is carried by the housing and a controller ismounted to the housing and to the motor for controlling the power supplyto the motor. In one embodiment, the controller is programmed to supplypower to the motor for a first predetermined period of time and todiscontinue power to the motor for a second predetermined period oftime. In a preferred embodiment of the invention, the controller has atimer that turns the motor off after a predetermined period of time forunattended cleaning of a spot on a floor surface, such as a carpet.

In one embodiment of the invention, the fluid supply system comprises afirst fluid tank with an outlet opening and a second fluid tank with anoutlet opening, wherein the outlet openings of the first fluid tank andthe second fluid tank are connected to supply a mixture of a a firstfluid from the first fluid tank and a second fluid from the second fluidtank to the fluid distributor. The outlet openings of the first fluidtank and the second fluid tank can be connected through a mixing valve.A controller is mounted to the housing and is connected to the mixingvalve, and the controller is programmed to control the relative amountsof the first and second fluids combined in the mixing valve. Thecontroller can be programmed to control the mixing valve to deliver apredetermined concentration of the first fluid and the second fluid tothe fluid distributor for a first predetermined length of time and todeliver the second fluid for a rinse cycle for a second predeterminedlength of time. The fluid supply system can further comprise acontrollable flow valve or a controllable pump between the mixing valveand the fluid distributor and the controller is connected to thecontrollable flow valve or controllable pump to control the flow offluid from the mixing valve to the fluid distributor. The controller canbe programmed to open the flow control valve or operate the pump duringa third predetermined period of time and to close the flow control valveor cease operation of the pump during a fourth predetermined period oftime.

In another embodiment of the invention, the fluid extraction systemfurther comprises a hose connected at one end to the housing and atanother end to a surface cleaning tool for extraction of fluids fromsurfaces other than beneath the opening in the underside of the housing.In addition, the fluid supply system can include a fluid supply conduitassociated with the hose and connected to the surface cleaning tool fordelivering fluids to areas other than beneath the opening in theunderside of the housing.

In yet another embodiment of the invention, a cord wrap element ismounted to the housing for movement between an extended position forwrapping an electrical cord in a compact configuration and a retractedposition for concealing the cord wrap element.

In yet another embodiment of the invention, an ion generator is mountedon the housing.

According to an important aspect of the invention is that a floorcleaner can be used in an unattended mode or can optionally be utilizedin a manual mode. A user identifies a stained portion of a surface to becleaned, e.g., a carpeted or upholstered surface, fills the spot cleanerwith necessary cleaning fluids, places the spot cleaner over the stain,and energizes the spot cleaner. The spot cleaner, without furtherintervention by the user, detects the condition of the surface to becleaned, applies the appropriate cleaning fluids, agitates the stainedportion as necessary, suctions excess cleaning fluids from the surface,and provides external status indications with respect to cleaningstatus. The user returns, at his or her convenience, to the spotcleaner, removes the spot cleaner from the surface to be cleaned, andmanually empties the excess fluid recovered during the cleaning process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of an unattended spot cleaningapparatus according to the invention.

FIG. 2 is a bottom perspective view of the unattended spot cleaningapparatus shown in FIG. 1.

FIG. 3 is a schematic sectional view taken along line 3-3 of FIG. 1 andshowing a fluid distribution system.

FIG. 4 is a schematic sectional view taken along line 4-4 of FIG. 1 andshowing a fluid recovery system.

FIG. 5 is an exploded view of the unattended spot cleaning apparatusshown in FIG. 1 with a portion of a top enclosure broken away.

FIG. 6 is an exploded view similar to FIG. 5 of a second embodiment ofan unattended spot cleaning apparatus according to the invention with avibrating platen.

FIG. 7 is a sectional view of the vibrating platen taken along line 7-7of FIG. 6.

FIG. 8 is a partial bottom view of the vibrating platen shown in FIG. 6.

FIG. 9 is an exploded view of a third embodiment of an unattended spotcleaning apparatus according to the invention.

FIG. 10 is an exploded view of a nozzle brush assembly of the unattendedspot cleaning apparatus shown in FIG. 9.

FIG. 11 is a partial sectional view taken along line 11-11 of FIG. 10.

FIG. 12 is a partial sectional view taken along line 12-12 of FIG. 10.

FIG. 13 is a bottom plan view of the unattended spot cleaning apparatusshown in FIG. 9.

FIG. 14 is a rear perspective view of a sixth embodiment of anunattended spot cleaning apparatus according to the invention.

FIG. 15 is a front perspective view of the unattended spot cleaningapparatus shown in FIG. 14.

FIG. 16 is an exploded view of the unattended spot cleaning apparatusshown in FIG. 14.

FIG. 17 is a perspective view of a bottom housing of the unattended spotcleaning apparatus shown in FIG. 14.

FIG. 18 is a perspective view of a cord wrap of the unattended spotcleaning apparatus shown in FIG. 14.

FIG. 19 is a sectional view of the cord wrap taken along line 19-19 ofFIG. 18.

FIG. 20 is an exploded view of a clean tank assembly of the unattendedspot cleaning apparatus shown in FIG. 14.

FIG. 21 is a perspective view of a cap assembly from the clean tankassembly shown in FIG. 20.

FIG. 22 is a perspective view of the unattended spot cleaning apparatusshown in FIG. 14 with a top housing removed to facilitate viewing of apump assembly.

FIG. 23 is an exploded view of a recovery tank assembly of theunattended spot cleaning apparatus shown in FIG. 14.

FIG. 24 is a sectional view of the recovery tank assembly taken alongline 24-24 of FIG. 23.

FIG. 25 is a perspective view of a carriage assembly of the unattendedspot cleaning apparatus shown in FIG. 16.

FIG. 26 is an exploded view of the carriage assembly shown in FIG. 25.

FIG. 27 is a bottom plan view of the carriage assembly shown in FIG. 25.

FIG. 28 is a sectional view of the carriage assembly taken along line28-28 of FIG. 27.

FIG. 29 is a sectional view of the carriage assembly taken along line29-29 of FIG. 27

FIG. 30 is a bottom perspective view of the carriage assembly shown inFIG. 25.

FIG. 31 is a perspective view of an alternative suction nozzle for thecarriage assembly shown in FIG. 30.

FIG. 32 is a sectional view of the unattended spot cleaning apparatustaken along line 32-32 of the FIG. 15.

FIG. 33 is a schematic view of a logic circuit of the unattended spotcleaning apparatus shown in FIG. 14.

FIG. 34 is an exemplary graph of dwell time for powered components ofthe unattended spot cleaning apparatus shown in FIG. 15.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings and in particular FIGS. 1-5, an unattendedspot cleaning apparatus 10 comprises an enclosure 12, a housing 14, afluid distribution system 11, a fluid recovery system 17, an agitationsystem 19, a drive rack assembly 21, floor condition sensors 23, and apower distribution system 25. At least a portion of the enclosure 12 ispreferably made of a transparent material so that the surface to becleaned is visible to the user. A U-shaped handle 13 is rotatablyattached to opposing side walls of the enclosure 12. The handle 13 is ofsufficient size so that a space is formed between a bottom surface ofthe handle 13 and a top surface of enclosure 12 when the handle 13 is inan upright position. Furthermore, the handle 13 is shaped so that a topsurface of the spot cleaning apparatus 10 is unobstructed when thehandle 13 is rotated to a horizontal position. A rack support structure16 is mounted to a top surface of the housing 14. The housing 14comprises a generally plate-like structure that is mounted to the bottomof the enclosure 12 and forms a cleaning aperture 18 that facilitatesdirect access of internal components of the spot cleaning apparatus 10to the surface being cleaned. A plurality of cylindrical grippers 15 arelocated on a bottom surface of the housing 14. Alternatively, thegrippers 15 can be replaced with a commonly known hook portion of a hookand loop fastening system or any other device that increases thefriction between carpet and the base 14 and, thus, minimizes relativemovement between housing 14 and the surface to be cleaned to minimizemovement between the spot cleaning apparatus 10 and the surface beingcleaned.

The fluid distribution system 11 comprises a first fluid tank 20removably mounted to a top of the enclosure 12. A second fluid tank 22is removably mounted adjacent to the first fluid tank 20 and also on thetop surface of the enclosure 12. A first cap 24 sealingly mates with anopening in the first fluid tank 20. A second cap 26 sealingly mates withan opening in the second fluid tank 22. The caps 24, 26 have a smallaperture therethrough to vent the respective tanks 20, 22. A recoverytank 28 is removably mounted to the top surface of the enclosure 12 andadjacent to the first fluid tank 20 and the second fluid tank 22. Arecovery tank cap 30 sealingly mates with an opening in the recoverytank 28. A power switch 32 is directly accessible to the user on anouter surface of the enclosure 12. Referring to FIG. 2, a distributionmanifold 34 is positioned within the cleaning aperture 18. A scrubbingimplement 36 is mounted parallel to the distribution manifold 34. Asuction nozzle 38 is located adjacent to the scrubbing implement 36. Thedistribution manifold 34, the scrubbing implement 36, and the suctionnozzle 38 are mounted on the rack support structure 16 and are movablelaterally therewith and within the cleaning aperture 18.

Referring to FIGS. 3 and 5, the fluid distribution system 11 furthercomprises a first outlet valve 42 located within an outlet opening ofthe first tank 20. The first outlet valve 42 is spring biased to aclosed position when first fluid tank 20 is removed from the spotcleaning apparatus 10. A protrusion associated with the enclosure alignswith the first outlet valve 42 and, upon engagement, overcomes thespring force to create an opening in fluid communication with a firstconduit 44. An example of a suitable outlet valve is disclosed in U.S.Pat. No. 6,467,122 to Lenkiewicz, which is incorporated herein byreference in its entirety. The first conduit 44 is in fluidcommunication with a first inlet into a mixing valve solenoid 46. Asecond outlet valve 48 is positioned in an outlet in the second fluidtank 22 in a fashion similar to that previously described for the firstfluid tank 20. The second outlet valve 48 is in fluid communication witha second conduit 50. The second conduit 50 is also in fluidcommunication with a second inlet to the mixing valve solenoid 46. Themixing valve solenoid 46 is electrically actuated and capable of varyingthe flow mixture of fluids from the first fluid tank 20 and the secondfluid tank 22. A single mixing valve outlet 52 allows mixed fluids fromthe first fluid tank 20 and the second fluid tank 22 to exit the mixingvalve solenoid 46. An example of a suitable mixing valve is disclosed inU.S. Pat. No. 6,131,237 to Kasper, which is incorporated herein byreference in its entirety. The mixing valve outlet 52 is in fluidcommunication with a fluid solenoid valve 54. The fluid solenoid valve54 is electrically controlled open and close a fluid delivery conduit56. The fluid delivery conduit 56 is in fluid communication with thespray nozzle 34. The distribution manifold 34 preferably comprises aplurality of apertures 58 along a lower surface of thereof.Alternatively, the distribution manifold 34 can be a spray nozzle. Ascan be appreciated, the size and number of the fluid tanks 20, 22 canvary. Furthermore, the fluid tanks 20, 22 can be flexible, collapsiblebladders as more fully described in U.S. Pat. No. 6,446,302 to Kasper etal., which is incorporated herein by reference in its entirety. Aplurality of chemical compositions including, but not limited to,detergent, oxidizers, disinfectants, miticides, fragrances, protectantsor other compounds, and other fluids, such as water, can be stored inthe fluid tanks 20, 22.

Alternatively, a pump can be used to provide fluid under pressure to thedistribution manifold 34. One such example is found in the previouslyreferenced U.S. Pat. No. 6,446,302 to Kasper et al.

In yet another alternative embodiment, the fluid tanks 20, 22 can bepressurized with an aerosol propellant. The fluid can be distributedthrough the previously described fluid solenoid valve 54 or through analternative delivery system. Optionally, a heater can be incorporatedwithin the fluid distribution system to heat the fluid to a temperatureless than boiling prior to reaching the surface to be cleaned. Oneexample of such a fluid heater can be found in U.S. Pat. No. 6,131,237to Kasper et al., which is incorporated herein by reference in itsentirety.

Referring to FIGS. 4 and 5, the fluid recovery system 17 furthercomprises the suction nozzle 38. The suction nozzle 38 has a relativelynarrow width aperture in close proximity to the surface being cleaned.An outlet of the suction nozzle 38 is in fluid communication with aflexible suction conduit 60. A second end of the flexible suctionconduit 60 is in fluid communication with an inlet standpipe 62. Theinlet standpipe 62 extends into recovery tank 28. A gasket assemblyseals the inlet standpipe 62 to the suction conduit 60 such that fluidcommunication is achieved when the recovery tank 28 is mounted to thetop of enclosure 12. An outlet standpipe 64 is mounted within therecovery tank 28 with a sealing gasket assembly similar to thatdescribed above for the inlet standpipe 62 so that fluid communicationis achieved when the recovery tank 28 is mounted to the enclosure 12.Alternatively, the air inlet and outlet through the recovery tank 28 canbe configured as shown in the commercially available BISSELL LittleGreen Clean Machine Model 1400, Model 1425, or Model 1425-1 portableextraction cleaner and disclosed in U.S. patent application Ser. No.10/065,891 to Lenkiewicz, which is incorporated herein by reference inits entirety. A fan housing with an inlet and an outlet is mountedwithin the enclosure 12. A fan 66 is rotatably mounted within the fanhousing. The inlet of the fan 66 is in fluid communication with theoutlet of the outlet standpipe 64. A fan motor 68 is in communicationwith the fan 66. In the first embodiment, the motor 68 is preferably anelectrical motor. When power is supplied to the fan motor 68, the fanmotor 68 turns a shaft that rotates the fan 66. As the fan 66 rotates,airflow is generated through the fan 66 and the fan housing. An exhaustaperture 70 is located on an outer surface of the enclosure 12 and is influid communication with the fan inlet 66.

The agitation system 19 comprises a scrubbing implement 36. In a firstembodiment, the scrubbing implement 36 is a brush roll mounted in ahorizontal position relative to the surface to be cleaned. A brush axle72 is located on a centerline axis of the scrubbing implement 36 andextends from both ends of the scrubbing implement 36. The brush drivebelt 74 rides on an outer surface of the brush axle 72. A brush motor 76is located within the enclosure 12 in close proximity to the scrubbingimplement 36. A motor shaft 78 extends from the brush motor 76 and is invertical alignment with the brush axle 72. A drive belt 74 is inoperative communication with both the motor shaft 78 and the brush axle72. Optionally, a pulley can be fixedly attached to both the motor shaft78 and the brush axle 72 to maintain the position of the drive belt 74on the shaft 78 and the axle 72. In the first embodiment, the brushdrive motor 76 is preferably an electrical motor. Power to the brushmotor 76 energizes the brush motor 76 to rotate the shaft 78, the belt74, the axle 72, and, therefore, the scrubbing implement 36. In a secondembodiment, the brush motor 76 can be an air turbine motor driven by thevacuum created by the fan 66.

Referring to FIG. 5, a rack drive assembly 21 comprises a rack supportstructure 16 and a drive rack 80. Opposing brush slots 82 extend throughone pair of opposing side walls of the rack support structure 16 andprovide a track on which the scrubbing implement 36 travels. Moreparticularly, the brush axle 72 coincides with the brush slots 82. Drivescrew bearings 84 are located on the other pair of opposing walls of therack support structure 16. A rack drive motor support 86 is locateddirectly above one of the drive screw bearings 84. The drive rack 80 isa generally U-shaped structure that comprises a suction nozzle support88 that is rigidly attached to suction nozzle 38. The drive rack 80further includes spray bar supports 90 located on a side opposite thesuction nozzle support 88. One end of the U-shaped drive rack 80comprises a pair of apertures. The top aperture, a brush drive shaftbearing 92, is located directly above the lower aperture, which is abrush axle bearing 94. The motor shaft 78 protrudes through the brushdrive shaft bearing 92. The axle shaft 72 protrudes through brush axlebearing 94. A drive screw threaded aperture 96 is located on acenterline of the drive rack 80. Male threads on the drive screwthreaded aperture 96 correspond with female threads on a drive screw 40.The drive screw 40 is threaded within the threaded aperture 96 fortravel in an axial direction. A drive screw motor 98 is positioned onthe rack drive motor support 86. One end of the drive screw 40 protrudesthrough the drive screw bearing 84. A drive screw motor shaft 100extends from a centerline of drive screw motor 98. The drive screw shaft100 is in vertical alignment with drive screw 40. The drive screw belt102 is in communication with the drive screw shaft 100 and the drivescrew 40. In the first embodiment, the drive screw motor 98 is anelectrical motor. The drive screw motor 98 rotates upon application ofpower, causing the shaft 100 to turn, which causes the belt 102 to turn,which then causes the drive screw 40 to turn. As the drive screw 40turns, the drive rack 80 is caused to move along the length of the drivescrew 40 due to the interference between the threaded aperture 96 andthe threads on the drive screw 40. When the drive rack 80 reaches theend of the travel in one direction, the female threads on the end of thedrive screw 40 are cut such that automatic reversal of the drive rackoccurs and the drive rack 80 proceeds along the length of the drivescrew 40 in an opposite direction. Similar reversing screw threaddesigns are incorporated on both ends of the drive screw 40 so that aslong as power is applied to the drive motor 98, the drive rack 80 willcontinuously work its way back and forth along the length of the drivescrew 40. Alternatively, the controller 106 reverses polarity on therack drive motor 98 to cause the rack 80 to reverse directions. Thespray nozzle 34, scrubbing implement 36, and suction nozzle 38 also movein correlation with the drive rack 80.

In a second embodiment, the rack drive assembly 21 comprises areversible motor mounted on the drive rack 80 and further comprises aspur gear fixedly attached to the motor shaft. The rack supportstructure comprises a gear rack on an upper wall that corresponds withthe spur gear on the motor. The controller 106 sends electrical outputto the reversible motor, which causes the rack drive assembly to move ina back and forth fashion across the rack support structure. In yetanother embodiment, gear racks are formed on the upper surface of twoopposite sides of the rack support structure. A second spur gear isrotatably attached to a side of the rack support structure opposite thereversible motor.

Referring to FIGS. 2 and 5, a plurality of floor condition sensors 23are located on an inside wall of the rack support structure 16. Thefloor condition sensors 23 are positioned to effectively scan the entirearea within the cleaning aperture 18 and measure the relative degree ofsoil on the surface being cleaned by sensing color variation. Thecontroller 106 is located between the enclosure 12 and the housing 14.The controller 106 comprises a commonly known printed circuit board uponwhich commonly known computer processing and electronic components aremounted. Batteries 108 are also located in the cavity between theenclosure 12 and the housing 14. The switch 32 selectively controlspower from the batteries 108. When switch 32 is on, power flows to thecontroller 106. The controller 106 receives inputs from the variouscondition sensors 104 and provides conditioned output to any combinationof the suction motor 68, brush drive motor 76, drive screw motor 98, thefluid solenoid valve 54 or the mixing valve solenoid 46. The floorcondition sensors 23 are mounted such that the entire area within thecleaning aperture 18 is monitored. Each sensor 23 provides signalsrelative to the condition of the surface being cleaned to the controller106 for processing. One such example of a controller and floor conditionsensors is disclosed in U.S. Pat. No. 6,446,302 to Kasper et al. issuedon Sep. 10, 2002, as previously referenced. Alternatively, thecontroller can utilize pre-timed programs in the fashion of a commonlyknown laundry washing machine timing circuit. In an alternateembodiment, the controller output signals are routed to a plurality ofvisual or audible indicators mounted to the exterior of the enclosure.Indicators can include Light Emitting Diodes (LED's) or signal tonegenerators. Indicators can convey information such as low fluid, thepresent stage of the cleaning cycle, or the like.

The batteries 108 can be any commonly known battery source includingalkaline or rechargeable nickel cadmium, nickel metal hydride or lithiummetal hydride. When rechargeable batteries are used, a commonly knownrecharging circuit is used to transform commonly available facilityvoltage to a level suitable for the batteries 108. A charging plugconnected to the transformer is manually or automatically attached tothe corresponding jack connected to the batteries 108 thereby completingthe circuit and allowing the batteries to charge. An example of such arecharging circuit can be found in the commercially availablerechargeable stick vacuum sold by BISSELL Homecare, Inc. under the nameGoVac or as disclosed in U.S. Pat. No. 6,345,411 to Kato, which isincorporated herein by reference in its entirety. In an alternateembodiment, the rechargeable batteries are eliminated and a direct wireto the facility outlet is supplied. In this configuration, the on/offswitch 32 is used to control power from the facility to the controller.

In operation, the user connects the unattended spot cleaning apparatus10 to facility power to energize the power circuit. Once a full chargeon the batteries 108 is reached, the user removes the charging circuitfrom the unattended spot cleaning apparatus 10. Typically, the userfills first fluid tank 20 with clean water or other suitable aqueouscompositions and the other fluid tanks with some type of detergent,protectant, miticide or any other application that is desired on thesurface to be cleaned. The user visually scans the surface to be cleanedand determines the particular location in which cleaning is desired. Theuser places the unattended spot cleaning apparatus 10 over the spot tobe cleaned. For spots that fit within the perimeter of aperture 18, aone-time use is all that is required. For spots larger than theperimeter of aperture 18, the steps described below must be repeated bymoving the apparatus 10 to the desired location for each succeedingcleaning. Once properly positioned, the on/off switch 32 is engaged andpower is delivered to the controller 106. The controller 106 controlsoutput based on information from the floor condition sensors 104.Typically, the drive rack assembly 80 will make a number of passes overthe area to be cleaned while the condition sensors 104 monitor thecondition of the surface to be cleaned. Depending on the condition ofthe floor being cleaned, the controller will generate signals to thevarious drive components. A typical sequence is as follows: the mixingvalve solenoid 46 is adjusted to provided the proper mixture of cleanwater in first fluid tank 20 and detergent or other secondary fluidcontained in the other fluid tanls; the fluid solenoid valve 54 isopened allowing mixed fluid to flow under force of gravity to the spraybar 34; the mixed fluid then drips from the apertures on the bottom offluid bar 34 as fluid bar passes over the area to be cleaned. Once floorcondition sensors 104 sense that adequate fluid has been deposited onthe floor (or the end of the pre-timed cycle is complete), the fluidsolenoid valve 54 is shut off, thus preventing fluid from flowing to thesurface to be cleaned. The controller 106 then sends a drive signal tothe brush motor 76 causing the scrubbing implement 36 to rotate. Thedrive rack assembly 80 continues to pass over the spot to be cleaned,now with the scrubbing implement 36 rotating. Once the condition sensors104 sense adequate agitation of the surface being cleaned, the signal tothe brush motor 76 is removed, causing the scrubbing implement 36 tostop rotation. Again, depending on signals delivered by the conditionsensors 104 the controller 106 then sends an output signal to thesuction motor 68. As the suction motor 68 turns, the fan generates anairflow as depicted by the arrows in FIG. 4. Loose debris and liquid atthe surface to be cleaned and within the proximity of the suction nozzle38 is lifted from the surface to be cleaned, carried through the suctionconduit 60 through the inlet standpipe 62 and deposited within theinterior of the recovery tank 28. Separation of air, debris and liquidoccurs within the interior of the recovery tank 28. Heavier solids andliquids fall to the bottom of the recovery tank 28. Working air is thendrawn into the outlet standpipe 64 and into the fan inlet 66. Workingair then passes through the fan 66 and is exhausted through the exhaustapertures 70. The condition sensors 104 and controller 106 continue toevaluate the condition of the surface being cleaned and selectively sendsignals as needed to the various drive components. Once the desiredlevel of cleanliness is achieved (or the pre-timed cleaning cycle ends),power to all of the drive components is removed and the unattended spotcleaning apparatus reverts to an idle mode. Upon returning to theunattended spot cleaning apparatus 10, the user turns off the electricalswitch 32, thus removing all power to the controller. The user removesthe recovery tank 28 from the enclosure 12 and debris from the recoverytank 28 is dumped into an appropriate disposal receptacle. Similarly,unused or excess fluid in the first fluid tank 20 and other fluid tanksare disposed of as needed or can be stored in the tank for future use.The unattended spot cleaning apparatus 10 is reattached to the chargingcircuit to replenish power to the batteries 108.

Referring to FIGS. 6, 7, and 8, in a third embodiment, the agitationsystem 19 can be a perforated vibrating platen. A plate 71 comprises atop surface 73, a bottom surface 75, and a plurality of apertures 77therethrough creating a perforated structure in constant contact withthe surface to be cleaned within cleaning aperture 18. Referring to FIG.8, the apertures 77 comprise a smaller opening 79 on the top surface 73and a larger opening 81 on the bottom surface 75 oriented in aconcentric fashion. Referring to FIG. 7, the concentric openings 73 and75 are joined by an arcuate wall to create a bugle-shaped opening 77through the plate 71. The larger openings 81 are located directlyadjacent one another in order to minimize the bottom surface 75 andmaximize the surface area of larger opening 81 in direct contact withthe surface to be cleaned. The openings 77, therefore, create aplurality of smaller suction nozzles spaced across the plate 71. Avertical support rod 83 is fixedly attached to the top surface 73 ineach of the four corners on the top surface 73 of the plate 71. Eachvertical support rod 83 corresponds to a guide aperture 85 formedthrough a support bracket 87 affixed to an upper inside wall of the racksupport structure 16. Three of the vertical support rods 83 are coveredwith a retaining cap 89 that moveably secures the plate 71 to the racksupport structure 16. The fourth support rod 83 is fixedly attached to atransmission 91. The transmission 91 is movably attached to a motorshaft, which in turn is affixed to a plate motor 93. The plate motor 93is fixedly attached to an upper surface of the rack support structure16. The transmission 91 converts rotational motion of the motor shaftinto lateral motion by the plate 71. High frequency vibrations aretransmitted through the plate 71 to the surface to be cleaned resultingin debris separating from the surface. Loose debris is then removed bythe fluid recovery system by creating suction above the plate 71 andthrough the bugle-shaped apertures 73 as previously described. In oneembodiment, the high frequency vibrations are ultrasonic.

In a fourth embodiment, the agitation system 19 is a sonic system thatremoves debris by directing sound waves to the surface to be cleaned ata specified frequency as disclosed in U.S. Pat. No. 3,609,787 to Aurelioet al., which is incorporated herein by reference in its entirety. Thesound waves create vibrations that separate debris from the surface tobe cleaned. The loosened debris can be removed as previously described.Referring to FIG. 9, in a fifth embodiment the unattended spot cleaner200 further comprises an enclosure 202, a base 204, a fluid distributionsystem 211, a fluid recovery system 217 and an agitation system 219. Theenclosure 202 further comprises a recess that accepts both the fluidtank 218, and the recovery tank 232. The enclosure 202 further comprisesa handgrip 206 located on an upper portion of the enclosure 202. Theenclosure 202 is preferably made of a transparent or translucentmaterial so that the area within the enclosure 202 is visible to theuser from outside the unattended spot cleaner 200.

The fluid distribution system 217 further comprises a spray manifold208, a solenoid valve 210, a pump 212, a pump gear 214, a fluid conduit216, and the fluid tank 218. All of the components in the fluiddistribution system are fluidly connected. The pump gear 214 meshes witha corresponding pinion gear 242 on a shaft extending from a fan motorassembly 240. The pump gear 214 corresponds with the pump 212 via ashaft. The solenoid valve 210 is electrically connected to thecontroller 241 for selectively distributing fluid to the spray manifold208 as previously described in the first embodiment.

The fluid recovery system 217 further comprises a nozzle brush assembly220 in fluid communication with a first conduit 222. A nozzle gear 224is fixedly attached to an exterior surface of the first conduit 222. Asealing slip ring 228 is attached to a second end of the first conduit222 opposite the nozzle brush assembly 220. The slip ring 228 sealinglymates with a second conduit 230 such that rotating motion between thefirst conduit 222 and the second conduit 230 can occur but motion alonga longitudinal axis of the first conduit 222 and the second conduit 230is minimized. The second conduit 230 is in fluid communication with therecovery tank 232, specifically at a recovery tank inlet 234 sealinglyformed at an aperture through an outer wall of recovery tank 232. Athird conduit 238 is in fluid communication with a recovery tank outlet236 sealingly formed at an aperture through a sidewall of recovery tank232. The third conduit 238 is in fluid communication with the motor fanassembly 240. A suction solenoid valve 239 selectively blocks airflowthrough the third conduit 238 on command from a controller 241 aspreviously described in the first embodiment. A motor shaft extendsthrough a fan portion of motor fan assembly 240 and further comprises amotor pinion gear 242. A gear reduction assembly comprises a shaft 244upon which a first reduction gear 246 is attached to one end of shaft244 and a second reduction gear 248 is attached to the other end ofshaft 244. In the assembly, the motor pinion gear 242 is in constantcommunication with the first reduction gear 246 and the second reductiongear 248 is in constant communication with the nozzle gear 244.

Referring to FIGS. 10 and 11, the nozzle brush assembly 220 furthercomprises a nozzle housing 250, a brush housing 252, and a plurality ofbristle brushes 254. A T-shaped brush drive shaft 256 is fixedlyattached to an inner surface of the second conduit 230 and extendsthrough the first conduit 222, the nozzle housing 250 and the brushhousing 252. A drive gear 258 is fixedly attached to the opposite end ofthe shaft 256 and further comprises a plurality of teeth on the outerperimeter thereof. The bristle brush 254 further comprises a brush gear260, a centrally located protrusion 255 on an upper face of the brushgear 260 and a plurality of bristles 261 attached to a lower surface ofthe brush gear 260. The protrusions 255 on the brush gear 260 extendthrough corresponding apertures 257 in the brush housing 252 and arestaked, capped, or otherwise suitably attached to the brush housing 252so that the bristle brush 254 is captured by the brush housing 252 andis allowed to rotate freely within aperture 257. The bristle brushes 254are spaced along the brush housing 252 so that the brush gears 260remain in contact and intermesh with one another. The drive gear 258 isstationary and also intermeshes with the brush gear 260 of the innermost bristle brushes 254.

The nozzle housing 250 nests over the brush housing 252 such that aninner wall of the nozzle housing 250 remains in spaced relation to anouter wall of the brush housing 252 thus creates a suction nozzle plenum262. The suction nozzle plenum 262 is in fluid communication with aninner surface of the first conduit 222 forming a part of a working airconduit that is in fluid communication with the motor fan assembly 240.Referring to FIGS. 11 and 13, when power is applied to the motor fanassembly 240 the motor shaft rotates causing the motor pinion 242 torotate. The motor pinion 242 is intermeshed with gear teeth of the firstreduction gear 246 that in turn causes the second reduction gear 248 torotate via the shaft 244. The gear teeth of the second reduction gear248 intermesh with the gear teeth of the nozzle gear 224. Since thenozzle gear 224 is fixedly attached to the first conduit 222 and thefirst conduit 222 is fixedly attached to the nozzle housing 250, theentire nozzle brush assembly 220 rotates about an axis formed by thebrush drive shaft 256. Since the brush drive shaft 256 and the drivegear 258 are fixed, the inner brush gears 260 that intermesh with thedrive gear 258 are also caused to rotate. Intermeshing of the outerbrush gears 260 with the inner brush gears 260 create a counter rotationas more clearly shown in FIG. 13 by arrows. Thus, as the nozzle brushassembly 220 rotates in a counterclockwise direction, the inner brushgears 260 are caused to rotate in counterclockwise direction and theouter brush gears 260 are caused to rotate in clockwise direction.

Referring again to FIG. 9, a plurality of floor condition sensors 263are mounted to an interior surface of the base 204 and operate in thesame manner as described for the preferred invention. A cord reelassembly 264 is mounted within the enclosure 202 and further comprises aspring-loaded reel that retracts a power cord about an internal drum.The power cord interfaces with facility electrical outlet and provideselectrical power to a switch 268 located on an upper surface of theenclosure 202. The switch 268 interrupts power to the controller 241.The controller 241 operates as previously described in the firstembodiment.

A sixth embodiment of a spot cleaning apparatus 500 for unattended ormanual cleaning of spots and stains on carpeted surfaces according tothe invention is illustrated in FIGS. 14-30. Referring particularly toFIGS. 14-16, the spot cleaning apparatus 500 comprises a bottom housingor portion 502, a top housing or portion 504, a clean tank assembly 506,a recovery tank assembly 508, a carriage assembly 510, a motor/fanassembly 512, and a pump assembly 514 The bottom housing 502 rests on asurface to be cleaned, and the top housing 504 and the bottom housing502 mate to form a cavity therebetween. A handle 516 is integrallyformed at an upper surface of the top housing 504 to facilitate easycarrying of the spot cleaning apparatus 500. A carriage assembly lens518 is attached to a forward lower section of the bottom housing 502 todefine an opening in the underside of the bottom housing 502 and ispreferably made from a transparent material for visibility of thecarriage assembly 510 located behind the carriage assembly lens 518.Hose recesses 520 are integrally formed in a lower surface of the tophousing 504 in forward and rearward locations. For explanatory purposes,the forward direction of the spot cleaning apparatus 500 is defined bythe location of the carriage assembly 510 and the carriage assembly lens518. The rearward direction is opposite of the forward direction.

Referring to FIGS. 16, 18, and 19, a cord wrap 522 is slidably mountedto a side surface of the top housing 504 and, in an extended position,supports a power cord (not shown) for easy storage thereof The cord wrap522 comprises an outer flange 526 and a generally elongated support tube528. The support tube 528 comprises one or more engagement detents 530on an end opposite the outer flange 526. The cord wrap 522 is mounted ina cord wrap aperture (not shown) in a side wall of the top housing 504.To insert the cord wrap 522 into the cord wrap aperture, the supporttube 528 is sufficiently deflected such that the engagement detents canpass through the cord wrap aperture 532. Once the engagement detents 530clear the cord wrap aperture, the support tube 528 returns to itsoriginal shape, and the engagement detents 530 contact an inner surfaceof the top housing 504 to retain the cord wrap 522 therein. The cordwrap extends laterally from the top housing 504, and the support tube528 provides a surface upon which the power cord can be wrapped. Thepower cord is mounted to the top housing 504 with a conventional strainrelief device. When the spot cleaning apparatus 500 is in use, the powercord is unwrapped from the cord wrap 522, and its free end is insertedinto or otherwise coupled with a conventional power outlet. With thepower cord removed, the cord wrap 522 can be pushed in toward the tophousing 504 to a retracted position wherein the outer flange 526 abutsthe top enclosure 504 to thereby effectively conceal the cord wrap 522for aesthetic purposes.

In an alternate embodiment, a pocket is formed around the cord wrapaperture such that the cord wrap 522 with the power cord wrapped thereoncan be pushed into the top housing 504 to achieve a clean, flushappearance for the spot cleaning apparatus 500 when not in use.

Referring to FIG. 15, a control panel 537 comprises a bezel to retain afirst operational mode switch 539, a second operational mode switch 541,a manual switch 543, and a plurality of corresponding indicator lights545 that visually communicate the operational mode of the spot cleaningapparatus 500 to the user. In use, the user selects the desiredoperational mode by engaging the appropriate switch 539, 541, or 543,which thereby sends an appropriate signal to the controller 106. Thecontroller 106 then sends appropriate output signals to components ofthe spot cleaning apparatus 500, as indicated in FIG. 33, as well as asignal to the appropriate indicator light 545 to communicate theoperational mode to the user.

The top housing 504 further comprises a suction hose assembly that canbe detached at one end from the spot cleaning apparatus for cleaning ina manual mode or attached to the spot cleaning apparatus at both endsduring an automatic mode. The suction hose assembly comprises a suctionhose fitting 536 preferably located on the same side as the cord wrap522. A flexible suction hose 538 is fixedly attached to and is in fluidcommunication with the suction hose fitting 536 via a commonly knownconnector. A suction hose grip 540 is fixedly attached to an oppositeend of the flexible suction hose 538. A suitable suction hose assemblyis disclosed in U.S. patent application Ser. No. 10/065,891 toLenkiewicz, which is incorporated herein by reference in its entirety. Ahose grip fitting 544 is fixedly attached between the top housing 504and the bottom housing 502 to removably retain the hose grip 540 to thespot cleaning apparatus 500. Various cleaning attachments can beremovably mounted to the hand grip 540 to manually perform specializedcleaning tasks in addition to or separate from the automatic unattendedfunction of the spot cleaning apparatus 500. When the suction hose 538is not utilized (i.e. during an automatic mode), it can be wrappedaround the top housing 504 so that the hose 538 rests in the hoserecesses 520 and the hose grip 540 is retained by the hose grip support.

Referring now to FIG. 17, the bottom housing 502 is a generally box-likestructure comprising a pair of generally vertical spaced side walls 546connected by a slightly arcuate rear wall 548 to form a spacetherebetween. The bottom housing 502 further comprises a motor/fansupport 550 between the side walls 546 and upon which the motor/fanassembly 512 rests. The motor/fan support 550 comprises a plurality ofapertures 552 therethrough to facilitate flow of exhaust and cooling airfor the motor/fan assembly 512. Exhaust and cooling air exits the spotcleaning apparatus 500 through a plurality of motor exhaust apertures553 formed in the side walls 564 and in fluid communication with theapertures 552. A plurality of ion inlet apertures 555 are located on oneside wall 546 while a plurality of ion outlet apertures 557 are locatedon the opposite side wall 546. The motor exhaust apertures 552 arephysically separated from the ion apertures 555, 557 by an ion generatorwall 559 to prevent mingling of the motor exhaust air and the ionizedair. The motor/fan assembly 512 working air path and cooling air pathare formed in a fashion similar to that disclosed in U.S. patentapplication Ser. No. 10/065,891 to Lenkiewicz. A platform-like carriageassembly support 554 is joined to upper edges of the side walls 546 andextends forwardly of the motor/fan support 550. The carriage assemblysupport 550 comprises a plurality of mounting apertures 556 to securethe carriage assembly 510 thereon. A central working air aperture 558extends through the carriage assembly support 554.

Referring to FIGS. 14-16, 20-22, and 33, a fluid delivery systemcomprises the clean tank assembly 506, a pump assembly 514, variousfluid supply conduits 564, and at least one fluid distribution member566. The clean tank assembly 506 comprises a first fluid tank assembly568, a second fluid tank assembly 570, and a clean tank cap assembly586. The first fluid tank assembly 568 comprises a blow molded fluidtank 574 with a single outlet aperture 576 disposed on a bottom surfacethereof. The first fluid tank 574 defines a cavity for storing a firstfluid. A recess 578 is formed in one surface of the first fluid tank 574for nestingly receiving the second fluid tank assembly 570. The recess578 and the second fluid tank assembly 570 are dimensioned such that theassembled fluid tank assemblies 568, 570 have the appearance of a singleunit with a smooth, uniform outer surface. The second fluid tankassembly 570 comprises a blow molded second fluid tank 580 with a singleoutlet aperture 582 disposed on a bottom surface thereof similar to thefirst fluid 574. The second fluid tank 580 comprises a protruding rearwall 584 that nestingly mates with the recess 578 on the first fluidtank 574. The second fluid tank 580 defines a cavity for storing asecond fluid. Both outlet apertures 576, 582 are sealingly covered bythe cap assembly 586.

In the preferred embodiment, the cap assembly 586 is a single cap frame588 with at least two cap apertures 590 corresponding to the outletapertures 576, 582. A commonly known umbrella valve 592 selectivelyseals the cap apertures 590. Desired mixing ratios between the the firstfluid drawn from the first fluid tank assembly 568 and the second fluiddrawn from the second fluid tank assembly 570 are determined by theorifice size of the apertures 590. When the spot cleaning apparatus 500includes a mixing valve 46, as described in the first embodiment, ratioof fluid mixtures can range from 100/0 first fluid/second fluid to 0/100first fluid/second fluid. The preferred ratio of the first fluid fromthe first fluid tank assembly 568 to the second fluid from the secondfluid tank assembly 570 is 80/20. Preferably, the first fluid is a 4% byweight hydrogen peroxide is mixed with 95% by weight distilled water,and the second fluid is a commonly known carpet cleaning detergent.Alternatively, the first fluid is a cleaning solution, such as acommonly known carpet cleaning composition, and the second fluid is aclear fluid, such as water. However, it is within the scope of theinvention for the first and second fluids to comprise other types offluids and for the first fluid to be the same as the second fluid.Optionally, either the first fluid or the second fluid can bedistributed without mixing with the other of the first fluid or thesecond fluid. For example, the first fluid can be distributed withoutdilution by the second fluid for concentrated cleaning, or the secondfluid can be distributed alone for rinsing.

Venting for the first and second fluid tank assemblies 568, 570 can beaccomplished in a conventional manner, such as vent holes in an uppersurface thereof, or vent tubes can be inserted into the fluid tanks 574,580 and vented to the atmosphere through the cap assembly 586 in amanner similar to that found in U.S. Pat. No. 6,125,498 to Roberts etal., which is incorporated herein by reference in its entirety.

In the preferred embodiment, the fluid tanks 574, 580 are pre-filledthrough the outlet apertures 567, 582 with a predetermined amount of thefirst and second fluids and sealed with the cap assembly 586 to form acaptive system wherein the fluid tanks 574, 580 can not be refilled bythe user. The clean tank assembly 506 is preferably purchased in thispre-filled state and is disposable when the supply of fluids therein isdepleted. Alternatively, the cap assembly 586 can be multiple piecesthat correspond to the respective outlet apertures 576, 582 and areremovable so that the user can refill the first and second fluid tankassemblies 568, 570 as needed.

Referring to FIGS. 22 and 33, the clean tank assembly 506 is locateddirectly above the pump assembly 514. The pump assembly 514 is mountedto a rear surface of the motor/fan support 550 in the bottom housing502. The pump assembly 514 comprises an electric motor 594 with a shaftdirectly coupled to a commonly known mechanical fluid pump 596 similarto that found in the BISSELL Spot Lifter Model 1725 and as disclosed inU.S. Pat. No. 6,125,498 to Roberts, which is incorporated herein byreference in its entirety. The fluid pump 596 comprises a pump inlet 598and a pump outlet 600. A pair of fluid conduits 564 fluidly communicatesthe outlet apertures 576, 582 with a common “T” fitting (not shown) onanother end. A first fluid conduit 564 fluidly communicates the “T”fitting on one end with the pump inlet 598 on another end. The fluidfrom the respective tanks 568, 570 mix in the “T” fitting and the firstfluid conduit 564 and are drawn into the fluid pump 596, which furthermixes the fluids. Mixed fluid is expelled from the fluid pump 596through the pump outlet 600. A second fluid conduit 564 fluidlycommunicates the pump outlet 600 with a fluid fitting (not shown) withinthe suction hose fitting 536. A third fluid conduit (not shown) runsfrom the fluid fitting and along the length of the suction hose 538. Atthe end of the suction hose 538, the third fluid conduit is fluidlyconnected to the grip support fitting 544. When the suction hose grip540 is coupled to the grip support fitting 544, the third fluid conduitis fluidly connected to a fourth fluid conduit 564 that is connected tothe grip support fitting 544 on one end. On the other end, the fourthfluid conduit 564 is connected to the at least one fluid distributionmember 566 preferably located underneath the carriage assembly support554 on the bottom housing 502. At the fluid distribution member 566, themixed fluid is applied to the surface to be cleaned. In one embodiment,the fluid distribution member 566 is a conventional spray nozzlepreferably mounted to the carriage assembly 510. In another embodiment,a fluid conduit terminates above the carriage assembly 510, and fluiddrips to the surface to be cleaned. In yet another embodiment, the fluiddistribution member 566 is a manifold with spaced openings. When thesuction hose grip 540 is removed from the grip support fitting 544, theuser can manually apply fluid to the surface to be cleaned. Refer toFIG. 33 for a schematic diagram of the fluid delivery system.

Referring to FIGS. 23-24, the recovery tank assembly 508, which is pairof a fluid extraction system, comprises a recovery tank 602 with singleaperture 604, a centrally mounted standpipe 606 within the tank 602 andin fluid communication with the aperture 604, and a float 608 slidinglyreceived on the standpipe 606. The recovery tank 602 is preferably blowmolded of a transparent material for visibility of the interior of therecovery tank 602. At least one alignment protrusion 610 on an outersurface of the tank 602 mates with a corresponding recess (not shown) onthe top housing 504 to maintain proper alignment of the tank 602relative to the top housing 504. The standpipe 606 is a generallyrectangular tube-like structure comprising an interior wall 612 thatdivides the interior of the standpipe 606 into two separate air paths: adirty air path 614 and a clean air path 616. A lower end of thestandpipe 606 defines a working air inlet 618 and a clean air outlet620. An upper end of the standpipe 606 comprises a deflector 622 and adirty air exhaust aperture 624 formed between a top wall of thestandpipe 606 and the deflector 622. A clean air inlet aperture 626formed in the standpipe 606 on a side opposite the dirty air exhaustaperture 624 is in fluid communication with the clean air path 616. Thefloat 608 comprises a shut off plate 628 that moves between an openposition and a closed position to open and close, respectively, theclean air inlet aperture 626. The open position is illustrated in FIG.24, and the shut off plate 628 moves from the open position to theclosed position when the debris and fluid in the recovery tank 602exceeds a predetermined volume.

As in the BISSELL Little Green Model 1425 and disclosed in U.S. patentapplication Ser. No. 10/065,891 to Lenkiewicz, the motor/fan assembly512 generates working air flow, and working/dirty air is drawn throughthe dirty air path 614 of the standpipe 606 via the working air inlet618. The dirty air is drawn through the dirty air path 614 and impactsthe deflector 622. Upon impact, the working air changes direction andslows, and the heavier dirt and liquid particles separate from theworking air and fall to the bottom of the recovery tank 602. Lighter,clean air is thereafter drawn over the top of the deflector 622 andenters the clean air path 616 via the clean air inlet aperture 626 inthe standpipe 606. The clean air travels down the clean air path 616 andthrough the clean air outlet 620 and is drawn into an inlet on themotor/fan assembly 512.

Referring to FIGS. 25-30, the carriage assembly 510 comprises aplurality of agitation assemblies 716 and suction nozzle assemblies 718.The carriage assembly 510 moves the agitation and suction nozzleassemblies 716, 718 through an orbital path to scrub the surface to becleaned and suction excess liquid therefrom. A circular main ring gear634 is rigidly attached to a bottom surface of the carriage assemblysupport 554 on the bottom housing 502 by a plurality of screws that passthrough circumferentially disposed screw bosses 636. A recess 638 isformed around the perimeter in a bottom surface of the main ring gear634. A plurality of ring gear teeth 640 formed on an inner perimeterdefines a ring gear aperture 642. A chamfer generally extending frominboard the recess 638 to outboard the gear teeth 640 forms an upperrace 643 of a bearing to be more fully described below. A cup-shapedgear motor well 644 with a corresponding gear motor aperture (not shown)formed through a bottom surface thereof extends tangentially from anouter perimeter of the ring gear 634. A commonly known gear box assembly648 comprising a gear motor 650 and a planetary gear box assembly 652are supported within the gear motor well 644. A motor pinion gear 654 iskeyed to an output shaft on the planetary gear box assembly 652. In analternate embodiment, the motor pinion gear 654 can be driven by amechanical crank powered by the user.

A drive plate assembly 656 comprises a bottom drive gear 658 and a topdrive plate 660. The bottom drive gear 658 comprises a plurality ofdrive gear teeth 662 on an outer perimeter that mesh with correspondingteeth on the motor pinion gear 654. A plurality of ball bearing sockets664 located inboard of the drive gear teeth 662 house corresponding ballbearings 666. A pinion gear aperture 668 is formed in an eccentricmanner on an inner perimeter of the bottom drive gear 658. A chamfer atan outer perimeter of the pinion gear aperture 668 serves as a race 670for a corresponding pinion gear assembly 672, which will be furtherdescribed hereinafter. The top drive plate 660 is a generally plate likedisc with a top pinion gear aperture 674 formed therethrough. A chamferat an outer perimeter of the top pinion gear aperture 674 serves as anupper race 676 for the pinion gear assembly 672. A plurality of ballbearing sockets 678 are located on an outer perimeter of the top driveplate 660 and correspond with the ball bearing sockets 664 on the bottomdrive gear 658. A plurality of screw bosses 680 provide locations forscrews that secure the bottom drive gear 658 to the top drive plate 660.

The pinion gear assembly 672 comprises an upper pinion gear 682 and alower pinion plate 684. The upper pinion gear 682 is a circular pan-likestructure with stiffening ribs 686 radiating from a central hub to anouter perimeter. A plurality of gear teeth 688 formed along an outerperimeter of the upper pinion gear 682 mesh with the corresponding ringgear teeth 640. An outer perimeter wall 690 comprises a plurality ofball bearing sockets 692 similar to those previously described on thebottom drive gear 658 and the top drive plate 660. Ball bearings 693similar to the ball bearings 66 reside partially within the ball bearingsockets 692. The upper pinion gear 682 includes an arched upper wall 691that forms an upper portion of a working air plenum 694. The lowerportion of the working air plenum 694 is defined by the lower pinionplate 684. A working air swivel fitting 696, which will be described infurther detail hereinafter, couples with the upper pinion gear 682 at atop surface thereof for fluid communication with the working air plenum694. A plurality of apertures (not shown) extend through the upperpinion gear 682 to receive a corresponding plurality of screws 695 tosecure the upper pinion gear 682 to the lower pinion plate 684.

The lower pinion plate 684 further comprises an outer perimeter wall 700with a plurality of ball bearing sockets 702 that correspond with theball bearing sockets 692 on the upper pinion gear 682. An arched lowerwall 704 in an upper surface of the lower pinion plate 684 forms thelower portion of the working air plenum 694. Hence, the working airplenum 694 is defined between the upper pinion gear 682 and the lowerpinion plate 684. A plurality of apertures on the bottom surface of thelower pinion plate 684 form working air inlets 706 for the working airplenum 694. The lower pinion plate 684 is secured to the upper piniongear 682 by a plurality of screws 695.

A circular agitation plate assembly 714 mounts the agitation assemblies716 and suction nozzle assemblies 718 to the carriage assembly 510. Thebasic structure for the agitation plate assembly 714 is provided by agenerally disc shaped agitation support plate 720. Each agitationassembly 716 comprises an agitation housing 724 with a plurality ofcommonly known brush bristles 726 protruding downwardly therefrom.Alternatively, other agitation devices or scrubbing implements can beused, such as a cloth and foam pads, in place of the bristles 726. Eachagitation assembly 716 is fastened to the agitation support plate 720 ina conventional manner with screws 729. A plurality of upwardlyprotruding bosses 728 on the agitation support plate 720 slidinglyengage an inner surface of a plurality of corresponding downwardlyprotruding screw bosses 730 on the lower pinion plate 684. Coil springs732 is positioned over the lower pinion plate screw bosses 730 arecaptured between a lower surface of the lower pinion plate 684 and anupper surface of the agitation support plate 720. The coil springs 732bias the agitation plate assembly 714 towards the surface to be cleanedto thereby facilitate enhanced agitation of the surface to be cleanedand seal the suction nozzles 734 with the surface to be cleaned. Thebiasing force is less than the weight of the housings 502, 504. Inaddition, the springs 732 absorb shock to minimize vibration of thecarriage assembly 510. Reduced vibration results in a lower tendency forthe unattended cleaner 500 to move or undesirably migrate duringoperation.

With particular reference to FIG. 30, the suction nozzle assemblies 718are shaped so as to maximize the coverage thereof over the surface to becleaned when moving in an orbital path. A suction nozzle 734 forms agenerally “T” shape at the surface to be cleaned. Alternative geometriesfor the suction nozzle 734 include narrow rectangular, oval, and “L”shaped openings, as illustrated in FIG. 31. A working air conduit isformed through the interior of the suction nozzle assembly 718 andterminating in a working air outlet 735 at an end opposite the suctionnozzle 734. A suction nozzle flange 736 surrounds around the working airoutlet 736 and provides an interface to sealingly couple the suctionnozzle assembly 718 to the agitation support plate 720.

A crescent shaped cover plate 740 mates with a bottom surface of thebottom drive gear 658 to prevent debris from entering the bearingsurfaces previously described. The cover plate 740 is essentiallycoplanar with the agitation support plate 720.

The carriage assembly 510 further comprises a retainer ring 742 thatsnaps into the recess 638 on the lower surface of the main ring gear634. The retainer ring 742 comprises a generally vertical outerperimeter wall 744 and a downwardly sloping chamfer on an inner surfaceto form a bottom race 746 of an outer bearing surface formed between themain ring gear 634 and the bottom drive gear 658.

The carriage assembly 510 is assembled by attaching the suction nozzleassemblies 718 and agitation assemblies 716 to the agitation supportplate 720. The agitation support plate 720 is mounted to the upperpinion gear 682 by screws that pass through the lower pinion plate 684.Before the agitation support plate 720 is fixed to the upper pinion gear682, the ball bearings 693 are positioned in the corresponding ballbearing sockets 692 so that they are captured between the upper piniongear 682 and the lower pinion plate 684. This assembly is mated with thebottom drive plate 658 so that the ball bearings 693 rest on the bottomdrive gear race 670. The top drive plate 660 is assembled to the bottomdrive plate 658 with the drive bear ball bearings 666 located in thecorresponding ball bearing sockets 664. The retainer ring 742 is placedon the bottom drive gear 658 so that the ball bearings rest on theretainer ring race 746. The partially assembled structure is raised intoposition with the main ring gear race 643 so that the ball bearings 666on the retainer ring race 746 contact the main ring gear race 643. Aflange 747 on an upper surface of the retainer ring 742 is press fit toengage the recess 638 on the lower surface of the main ring gear 634 tolock the drive plate assembly 656 to the main ring gear 634.

Operation of the carriage assembly 510 is herein described withreference to FIGS. 25-27 and 30. When power is supplied to the gearmotor 650, the shaft rotates and induces rotation of the motor piniongear 654. The teeth of the motor pinion gear 654 mesh with the bottomdrive gear teeth 662, thereby causing the bottom drive gear 658 torotate about its centerline. As the bottom drive gear 658 rotates, thepinion gear assembly 672 rotates in an opposite direction about itscenterline. Since the pinion gear aperture 668 is off center relative tothe centerline of the bottom drive gear 658, the pinion gear assembly672 and, thus, agitator plate assembly 714, the agitation assemblies716, and the suction nozzle assemblies 718, move in an orbital motion.In other words, the pinion gear assembly 672 rotates about its owncenterline while orbiting about the centerline of the bottom drive gear658. The agitation assemblies 716 and the suction nozzle assemblies 718,therefore, move laterally relative to the surface to be cleaned andrelative to the bottom housing 502, which remains stationary. Thecounter-rotational movement of the pinion gear assembly 672 is caused bya cam action, since the pinion gear assembly 672 is captured within thedrive plate assembly 656 in an offset position. Because the gear teeth688 on the upper pinion gear 682 engage with the fixed teeth 640 on themain ring gear 634, the rotation of the pinion gear assembly 672 isgenerated independent of the rotation of the drive plate assembly 656.The orbital motion ensures that all of the area under the carriageassembly support 554 is cleaned. Alternatively, the agitator plateassembly 714 can be aligned with the centerline of the bottom drive gear658 so that the agitator plate assembly 714 rotates in a simple circularmanner about a single axis. However, the orbital motion is preferredbecause the agitator assemblies 716 can completely cover the area underthe agitator plate assembly 714 and cleans the center of the axis ofrotation as well as the outer periphery of the agitator assemblies 716and suction nozzle assemblies 718.

The working air path of the spot cleaning apparatus 500 is illustratedin FIG. 32. The working air generated by the motor/fan assembly 512 isdrawn from the surface to be cleaned through the suction nozzles 734,through the working air outlets 735 of the suction nozzle assemblies718, into the working air plenum 694 defined between the upper piniongear 682 and the lower pinion plate 684, and up through the swivelfitting 696. The working air flows through a flexible hose (not shown)connected to the swivel fitting 696 on one end and the suction hosefitting 536 on the other end. The working air flows through the suctionhose 538 to the suction hose grip 540. When the spot cleaning apparatus500 is being used in the manual mode, the user removes the suction hosegrip 540 from the grip support fitting 544 and maneuvers the suctionhose grip 540 and any tools attached thereto over the surface to becleaned in a conventional manner. When the cleaning apparatus 500 isbeing used in the automatic or unattended mode, the suction hose grip540 remains connected to the grip support fitting 544 to thereby fluidlyconnect the working air path from the suction hose 538 and through thesuction hose grip 540 and grip support fitting 544 to a fixed workingair conduit positioned within the bottom housing 502. The fixed workingair conduit is coupled with the working air inlet 618 on the standpipe606 in the recovery tank 602. The working air moves up through the dirtyair path 614, impacts the deflector 622, and exits the standpipe 606through the dirty air exhaust aperture 624 where solid debris falls fromthe air and settles under force of gravity to the bottom of the recoverytank 602. The clean air is then drawn into the clear air inlet aperture626, down the clean air path 616 of the standpipe 606, out the clean airoutlet 620, and into a clean air conduit 762 that is fluidly connectedto an inlet on the motor/fan assembly 512. Exhaust air from themotor/fan assembly 512 exits the bottom housing 502 through the exhaustair apertures 553.

Referring to FIGS. 16 and 17, an optional ion generator 770 is locatedwithin the cavity formed between the top housing 504 and the bottomhousing 502. The ion generator 770 uses electricity to create a spark inan air space. The spark creates ozone which is helpful in removing odorsfrom the surrounding air. A similar ion generating device is more fullydescribed in U.S. Pat. No. 2,297,933 to Yonkers, which is incorporatedherein by reference in its entirety. The ion generator providesadditional utility by functioning as a room air cleaner when the spotcleaning apparatus 500 is not being utilized for cleaning stains andspots from the carpet or other surface. Alternatively, the ion generator770 can be placed anywhere in the working air path to provide additionalcleaning or odor reduction benefits at the suction nozzle 734, in therecovery tank assembly 508, or near the motor exhaust apertures 553.Such a system is more fully described in U.S. Pat. No. 2,297,933 toYonkers, U.S. Pat. No. 5,920,954 to Sepponen, and Japan Publication No.7327873, all of which are incorporated herein by reference in theirentirety.

The unattended cleaning apparatus 500 can be operated as an unattendedspot cleaner, a manual spot cleaner, and optionally as a portable roomair cleaner. To prepare the spot cleaning apparatus for use as theunattended spot cleaner or the manual spot cleaner, a pre-filled cleantank assembly 506 is placed on the top housing 504 above the pumpassembly 514. When the clean tank assembly 506 is mounted onto the tophousing 504, the umbrella valves 592 automatically open for fluid flow.The user positions the unattended cleaning apparatus 500 over the spotto be cleaned so that the agitation plate assembly 714 is centered overthe spot. The user plugs the power cord into a convenient receptacle andselects a desired duty cycle by pressing one of the switches 539, 541,or 543 located on the top housing 504, which thereby powers thecontroller.

A graph depicting dwell time for powered components of the unattendedspot cleaning apparatus 500 during an exemplary light duty cycle ispresented as FIG. 34. During the light duty cycle, fluid can bedelivered in three separate applications while simultaneously extractingspent fluid for an approximately 60 and 90 second suction intervals.Preferably, one half of the available fluid is dispersed immediatelyupon activation of the spot cleaning apparatus 500, followed by twoadditional fluid applications cycles, wherein each additional fluidapplication cycle delivers approximately one quarter of the initialvolume. Preferably, the cleaning fluid is delivered at a flow rate of1000 mL/minute. As schematically indicated by the dwell time in FIG. 34for the mixing valve 46, if utilized, and the fluid pump assembly 514,the preferred fluid delivery cycle comprises 4.5 seconds on, 25.5seconds off, 2.25 seconds on, 27.75 seconds off, and a final 2.25seconds on. The gear motor 650 runs constantly throughout the light dutycycle to constantly move the agitation plate assembly 714. Suctionremains active except for 30 seconds between the 60 second and 90 secondintervals. The total duration of the light duty cycle is approximately 4minutes. An exemplary heavy duty cycle completes two of theaforementioned cycles in series for a total run time of 8 minutes. Otherduty cycles can be programmed into the controller 106 to vary the fluiddelivery, the fluid mixing through the mixing valve 46, agitation, andsuction dwell times. Further, the duty cycles can include a non-powereddwell time wherein the fluids are allowed to penetrate and work on thespot while all other functions are temporarily suspended. At aconvenient time for the user, the user returns to the unattended spotcleaning apparatus 500, unplugs the power cord, removes the recoverytank assembly 508 from the top housing 504, and cleans the recovery tankassembly 508.

The optional ion generator 770 can be powered at any time (i.e., whetherthe spot cleaning cycle is running or not) to provide constant aircleaning. In another embodiment, the ion generator 770 is controlled bya separate switch or by sensors and the controller 106 for optimumautomatic run time.

The preferred invention has been described as an unattended spotcleaning apparatus. It can also be appreciated that several subsets ofthe invention can be recombined in new ways to provided variousconfigurations. Any combination of a floor condition sensor system,fluid distribution system, fluid recovery system, or agitation systemcan be used to solve specific cleaning problems not requiring all thecapabilities of all the subsystems herein described.

While the invention has been specifically described in connection withcertain specific embodiments thereof, it is to be understood that thisis by way of illustration and not of limitation. For example, theinvention can be practiced with a single fluid tank as well as multiplefluid tanks with a mixer for the fluids from the multiple fluid tanks.Reasonable variation and modification are possible within the scope ofthe forgoing description and drawings without departing from the scopeof the invention that is described in the appended claims.

1. A floor cleaning apparatus comprising: a housing with a bottomportion that is adapted to rest on a surface being cleaned and acarriage assembly support above an opening in an underside of thehousing; a fluid delivery system mounted to the housing and including afluid distributor for delivering a cleaning fluid to the surface to becleaned beneath the opening in the underside the housing; a fluidextraction system including a suction nozzle for recovering soiledcleaning fluid from the surface to be cleaned beneath the opening in theunderside of the housing; and a carriage mounting the fluid distributorand the suction nozzle to the carriage assembly support fortranslational movement with respect to the housing so that the suctionnozzle and the fluid distributor move laterally with respect to thesurface to be cleaned.
 2. The floor cleaning apparatus according toclaim 1 and further including a scrubbing implement mounted to thecarriage for movement with the fluid distributor and the suction nozzleand for scrubbing contact with the surface to be cleaned.
 3. The floorcleaning apparatus according to claim 2 wherein the scrubbing implement,the fluid distributor, and the suction nozzle move as a unit withrespect to the housing.
 4. The floor cleaning apparatus according toclaim 3 wherein the translational movement is orbital.
 5. The floorcleaning apparatus according to claim 4 wherein the carriage comprises agear system for motion of the fluid distributor and the suction nozzlewith respect to the housing.
 6. The floor cleaning apparatus accordingto claim 3 wherein the translational movement is linear.
 7. The floorcleaning apparatus according to claim 3 wherein the translationalmovement is circular.
 8. The floor cleaning apparatus according to claim2 wherein the scrubbing implement is a brush.
 9. The floor cleaningapparatus according to claim 2 wherein the scrubbing implement is acloth.
 10. The floor cleaning apparatus according to claim 2 wherein thescrubbing implement is a foam pad.
 11. The floor cleaning apparatusaccording to claim 3 wherein the distributor comprises at least onespray nozzle.
 12. The floor cleaning apparatus according to claim 3wherein the distributor is a manifold with spaced openings.
 13. Thefloor cleaning apparatus according to claim 1 wherein the suction nozzleis L-shaped.
 14. The floor cleaning apparatus according to claim 1wherein the suction nozzle is T shaped.
 15. The floor cleaning apparatusaccording to claim 1 and further comprising a motor mounted to thehousing and connected to the carriage for driving the translationalmovement of the carriage with respect to the housing.
 16. The floorcleaning apparatus according to claim 15 and further comprising a powersupply for the motor carried by the housing and a controller mounted tothe housing and to the motor for controlling the power supply to themotor.
 17. The floor cleaning apparatus according to claim 16 whereinthe controller is programmed to supply power to the motor for a firstpredetermined period of time and to discontinue power to the motor for asecond predetermined period of time.
 18. The floor cleaning apparatusaccording to claim 1 wherein the fluid supply system comprises a firstfluid tank with an outlet opening and a second fluid tank with an outletopening, wherein the outlet openings of the first fluid tank and thesecond fluid tank are connected to supply a mixture of-first and secondfluids from the first fluid tank and the second fluid tank to the fluiddistributor.
 19. The floor cleaning apparatus according to claim 18wherein the outlet openings of the first fluid tank and the second fluidtank are connected through a mixing valve.
 20. The floor cleaningapparatus according to claim 19 and further comprising a controllermounted to the housing and connected to the mixing valve, and thecontroller is programmed to control the relative amounts of the firstand second fluids combined in the mixing valve.
 21. The floor cleaningapparatus according to claim 20 wherein the controller is programmed tocontrol the mixing valve to deliver a predetermined concentration of thefirst fluid and the second fluid to the fluid distributor for a firstpredetermined length of time and to deliver only the second fluid for arinse cycle for a second predetermined length of time.
 22. The floorcleaning apparatus according to claim 21 wherein the fluid supply systemfurther comprises a controllable flow valve or a controllable pumpbetween the mixing valve and the fluid distributor and the controller isconnected to the controllable flow valve or controllable pump to controlthe flow of fluid from the mixing valve to the fluid distributor. 23.The floor cleaning apparatus according to claim 22 wherein thecontroller is programmed to open the flow control valve or operate thepump during a third predetermined period of time and to close the flowcontrol valve or cease operation of the pump during a fourthpredetermined period of time.
 24. The floor cleaning apparatus accordingto claim 1 wherein the fluid extraction system further comprises a hoseconnected at one end to the housing and at another end to a surfacecleaning tool for extraction of fluids from surfaces other than beneaththe opening in the underside of the housing.
 25. The floor cleaningapparatus according to claim 24 wherein the fluid supply system furtherincludes a fluid supply conduit associated with the hose and connectedto the surface cleaning tool for delivering fluids to areas other thanbeneath the opening in the underside of the housing.
 26. The floorcleaning apparatus according to claim 1 and further comprising a cordwrap element mounted to the housing for movement between an extendedposition for wrapping an electrical cord in a compact configuration anda retracted position for concealing the cord wrap element.
 27. The floorcleaning apparatus according to claim 1 and further comprises aresilient biasing element between the carriage and the carriage assemblysupport for resiliently biasing the suction nozzle and the scrubbingimplement, if any, onto the surface to be cleaned.
 28. The floorcleaning apparatus according to claim 26 wherein the biasing force ofthe biasing element is less than the weight of the housing.
 29. Thefloor cleaning apparatus according to claim 1 and further comprising anion generator mounted on the housing.
 30. The floor cleaning apparatusaccording to claim 1 and further comprising a sonic generator mounted tothe housing for directing sound waves to the surface to be cleaned at afrequency that loosens debris from the surface.
 31. The floor cleaningapparatus according to claim 1 and further comprising a plurality ofcondition floor sensors mounted to the housing for detecting the levelof soil on the floor to be cleaned and for generating a control signalrepresentative thereof.
 32. (canceled)
 33. (canceled)
 34. The floorcleaning apparatus according to claim 1 wherein the translationalmovement is orbital.
 35. The floor cleaning apparatus according to claim1 wherein the translational movement is linear.
 36. The floor cleaningapparatus according to claim 1 wherein the translational movement iscircular.
 37. The floor cleaning apparatus according to claim 1 whereinthe distributor comprises at least one spray nozzle.
 38. The floorcleaning apparatus according to claim 1 wherein the distributor is amanifold with spaced openings.